Connecting Components for Photovoltaic Arrays

ABSTRACT

The invention includes an apparatus for mounting a photovoltaic (PV) module onto a structure where the apparatus includes a base portion, a stud portion, and a coupling portion. The coupling portion includes a male portion that acts as a spring under load and a clip portion that penetrates the PV module frame to create a grounding bond. The apparatus includes a lower jaw, shaped to pry open a groove, and a key portion that can compress to allow for tolerances. The invention further includes a clip with one or more tabs and one or more teeth. The invention further includes a replacement roof tile which includes a support structure with a horizontal flange, a vertical component, a horizontal component, a flashing with an upper surface and a lower surface, and a tile-shaped metal surface having a curvilinear shape that reflects the shapes of adjacent tiles.

CROSS REFERENCES

The present application is a continuation in part of U.S. applicationSer. No. 13/325,054, filed Dec. 13, 2011, and claims the benefit of thefiling date of U.S. Provisional Patent Application Ser. No. 61/737,066filed Dec. 13, 2012.

BACKGROUND

Solar panels and related equipment are frequently mounted on supportstructures (such as roofs), or other objects that require asubstantially water-tight or water resistant connection. For example,solar panels mounted on a tiled roof of a building are commonly attachedto the roof via an attachment system that includes a roof hook orflashing device that allows a roof-penetrating member, such as a lagscrew, to penetrate a portion of a roofing membrane without compromisingthe roof's ability to prevent water from entering the building. Priorart attempts to develop such flashing devices have suffered from anumber a drawbacks. For example, most flashings are flat and lack theability to mount solar panels or related equipment on Spanish tile or Stiled roofs. Most conventional flashings are designed for shingled ormetal roofs and would require cutting or modifying tiles forinstallation. Other flashing devices do not provide adequate pressure onthe seal around the lag screw. Others do not allow for a separatelypositionable bracket that enables adjustability relative to the lagscrew after installation thereof. Others do not work well with rail-freemounting systems such as those disclosed in prior art patents and otherpatents and applications of common assignee and at least one commoninventor. Others do not comprise a support portion with multiple holesor slots for connecting brackets and/or other devices in variouspositions to allow for connection to different locations along aphotovoltaic (“PV”) module frame. And still others are costly, do notoptimize materials usage, create seals from brittle materials that havehigher failure rates than resilient materials, require expensivemanufacturing methods, and/or do not properly account for misalignmentof components during installation. The foregoing examples of the relatedart and limitations related therewith are intended to be illustrativeand not exclusive. Other limitations of the related art will becomeapparent to those of skill in the art upon a reading of thespecification and a study of the figures.

SUMMARY

The following embodiments and aspects thereof are described andillustrated in conjunction with systems, apparatus, tools, and methodswhich are meant to be exemplary and illustrative, not limiting in scope.In various embodiments, one or more of the above-described problems havebeen reduced or eliminated, while other embodiments are directed toother advantages or improvements.

One embodiment of the invention comprises an apparatus for mounting a PVmodule on a structure where the apparatus includes a base portion, astud portion, and a coupling portion. The coupling portion comprises amale portion that may act as a spring under load and a clip portion thatmay penetrate the PV module frame to create a grounding bond. Theapparatus includes a lower jaw shaped to pry open a groove. Theapparatus further includes a key portion that can compress to allow fortolerances. One embodiment of the invention further comprises a methodfor mounting PV modules on a structure comprising (i) securing the baseof a leveling foot to a substrate or structure, (ii) inserting the keyportion of the coupling into the groove of a PV module at an anglebetween five and seventy-five degrees, (iii) rotating the PV moduledownward toward the substrate or structure until it is parallel with thesubstrate or structure, causing the key portion to fully engage thegroove, causing spring contraction of the key, and causing springexpansion of the groove, (iv) resting the outside surface of the frameof a second PV module on the top surface of the coupling portion suchthat the second PV module is at a ninety degree angle to the substrate,and (v) rotating the second PV module downward until roughly parallelwith the first PV module. One embodiment of the invention facilitatesease of mounting, allows for greater tolerances, and provides electricalgrounding between components. One embodiment of the invention furthercomprises a clip comprising one or more tabs and one or more teeth wherethe tabs secure the clip to a coupling portion of a leveling foot andthe teeth penetrate (i) the exterior surface of a PV module when the PVmodule engages the coupling portion and (ii) a surface of the couplingportion when the clip engages the coupling portion, thereby creating aground bond between the clip, the coupling portion, and the PV module.One embodiment of the invention improves and simplifies electricalgrounding between components. One embodiment of the invention furthercomprises a replacement roof tile including a support structure with ahorizontal flange, a vertical component, and a horizontal component, aflashing with an upper surface and a lower surface, and a tile-shapedmetal surface having a curvilinear shape that reflects the shapes ofadjacent tiles. One embodiment of the invention facilitates theinstallation of PV arrays on tile roofs, reduces installation time, andimproves aesthetics. Lastly, the invention further comprises a methodfor mounting a replacement roof tile comprising mounting a supportstructure to a substrate, mounting a tile-shaped metal surface on asupport structure, mounting a top arm to a support structure over,above, or atop a tile-shaped metal surface, mounting a leveling foot toa top arm, and mounting a PV module to a leveling foot. One embodimentof the invention facilitates the benefits of the replacement roof tile.

In addition to the exemplary aspects and embodiments described above,further aspects and embodiments will become apparent by reference to thefigures and by study of the following detailed descriptions.

BRIEF DESCRIPTION OF THE DRAWINGS

Demonstrative embodiments are illustrated in referenced figures anddrawings. It is intended that the embodiments and figures disclosedherein are to be considered illustrative rather than restrictive.

FIG. 1 is an isometric view of a leveling foot.

FIG. 2 is an orthogonal view of a leveling foot.

FIG. 3 is an isometric view of the underside of a leveling foot.

FIG. 4 is a cross-section of a bisected leveling foot.

FIG. 5 is an isometric view of the clip of a leveling foot.

FIG. 6 is a cross section of a bisected leveling foot with one PV moduleinstalled and one PV module placed atop the leveling foot as an initialinstallation step.

FIG. 7 is a cross-section of a bisected leveling foot with the PV modulefrom FIG. 6 rotating downward to complete its installation.

FIG. 8 is an enlarged view of section A from FIG. 7.

FIG. 9 is an isometric view of a replacement tile installed on a roofwith a top arm and leveling foot installed.

FIG. 10 is an orthogonal view of the installation shown in FIG. 9 wherehidden components are detailed with dashed lines.

FIG. 10A is an isometric view of a replacement tile.

FIG. 11 is an isometric view of a roof with a roof tile removed inanticipation of the installation of a replacement tile and relatedcomponents.

FIG. 12 is an isometric view of a roof with a roof tile removed and asupport structure installed.

FIG. 13 is an isometric view of a roof with a roof tile removed and areplacement tile installed atop a support structure.

FIG. 14 is an isometric view of a roof with a roof tile removed and areplacement tile installed atop a support structure with a top arminstalled atop the replacement tile and support structure.

FIG. 15 is an isometric view of a roof with a roof tile removed and areplacement tile installed atop a support structure with a top arminstalled atop the replacement tile and support structure and a levelingfoot installed atop the top arm.

FIG. 16 is an isometric view of a top arm.

FIG. 17 is an orthogonal view of a top arm.

FIG. 18 is a bottom view of a top arm.

FIG. 19 is an orthogonal view of components of an embodiment of asupport structure.

FIG. 20 is an isometric view of a roof with a roof tile removed and areplacement tile installed atop a support structure with a leveling footinstalled atop the replacement tile and support structure.

FIG. 21 is an isometric view of a roof with a roof tile removed and areplacement tile installed atop a support structure with a top arminstalled atop the replacement tile and support structure and a levelingfoot installed atop the top arm.

FIG. 22 is an orthogonal view of a roof with a roof tile removed and areplacement tile installed atop a support structure with a top arminstalled atop the replacement tile and support structure and a levelingfoot installed atop the top arm.

FIG. 23 is an isometric view of a replacement tile.

FIG. 24 is an isometric view of a top arm.

FIG. 25 is a top view of a top arm.

FIG. 26 is a side view of a top arm.

FIG. 27 is a bottom view of a top arm.

FIG. 28 is a front view of a top arm.

FIG. 29 is an isometric view of a roof with a roof tile removed and asupport structure installed.

FIG. 30 is an isometric view of a roof with a roof tile removed and areplacement tile installed atop a support structure.

FIG. 31 is an isometric view of a roof with a roof tile removed and areplacement tile installed atop a support structure with a top arminstalled atop the replacement tile and support structure.

FIG. 32 is an isometric view of a roof with a roof tile removed and areplacement tile installed atop a support structure with a top arminstalled atop the replacement tile and support structure and a levelingfoot installed atop the top arm.

FIG. 33 is an isometric view of a roof with a roof tile removed and areplacement tile installed atop a support structure with a top arminstalled atop the replacement tile and support structure and a levelingfoot installed atop the top arm.

FIG. 34 is an orthogonal view of a roof with a roof tile removed and areplacement tile installed atop a support structure with a top arminstalled atop the replacement tile and support structure and a levelingfoot installed atop the top arm.

FIG. 34A is a view of the underside of a top arm.

FIG. 35 is an isometric view of a replacement tile.

FIG. 36 is an isometric view of a roof with a roof tile removed and asupport structure installed.

FIG. 37 is an isometric view of a roof with a roof tile removed and areplacement tile installed atop a support structure.

FIG. 38 is an isometric view of a roof with a roof tile removed and areplacement tile installed atop a support structure with a top arminstalled atop the replacement tile and support structure.

FIG. 39 is an isometric view of a roof with a roof tile removed and areplacement tile installed atop a support structure with a top arminstalled atop the replacement tile and support structure and a levelingfoot installed atop the top arm.

FIG. 40 is an isometric view of a roof with a roof tile removed and asupport structure installed.

FIG. 41 is an isometric view of a replacement tile.

FIG. 42 is an alternate view of a replacement tile.

FIG. 43 is an isometric view of a roof with a roof tile removed and areplacement tile installed atop a support structure.

FIG. 44 is an isometric view of a roof with a roof tile removed and areplacement tile installed atop a support structure where one cap hasbeen removed to reveal an aperture.

FIG. 45 is an isometric view of a roof with a roof tile removed and areplacement tile installed atop a support structure with a leveling footinstalled atop the replacement tile and support structure.

FIG. 46 is an orthogonal view of a roof with a roof tile removed and areplacement tile installed atop a support structure with a top arminstalled atop the replacement tile and support structure and a levelingfoot installed atop the top arm.

FIG. 47 is an isometric view of a replacement tile.

FIG. 48 is a bottom view of a leveling foot engaging a top arm.

FIG. 49 is an isometric view of a roof with a roof tile removed and asupport structure installed.

FIG. 50 is an isometric view of a roof with a roof tile removed and areplacement tile installed atop a support structure.

FIG. 51 is an isometric view of a roof with a roof tile removed and areplacement tile installed atop a support structure with a top arminstalled atop the replacement tile and support structure.

FIG. 52 is an isometric view of a roof with a roof tile removed and areplacement tile installed atop a support structure with a top arminstalled atop the replacement tile and support structure and a levelingfoot installed atop the top arm.

FIG. 53 is an isometric view of a flashing mount.

FIG. 54 is a cross section orthogonal view of a bisected flashing mount.

FIG. 55 is an isometric view of a PV module connecting to a flashingmount.

FIG. 56 is an enlargement of section B of FIG. 55.

FIG. 57 is an exploded view of a leveling foot and a coupling for atrapezoidal roof

FIG. 58 is a rear orthogonal view of a leveling foot connected to atrapezoidal roof using a coupling.

FIG. 59 is an exploded view of a leveling foot and a coupling for atrapezoidal roof

FIG. 60 is an isometric view of a PV module connecting to a top armusing a dream clip.

FIG. 61 is an orthogonal view of FIG. 60.

FIG. 62 is a top view of FIG. 60.

FIG. 63 is a top view of FIG. 60.

FIG. 64 is a top view of FIG. 60.

FIG. 65 is an isometric view of a support structure with a top arm.

FIGS. 66-68 are views of a wire clip.

FIGS. 69-71 are views of a wire clip.

FIGS. 72-74 are views of a wire clip.

DETAILED DESCRIPTION OF ONE OR MORE EMBODIMENTS OF THE INVENTION Terms

With reference to the figures and description herein but withoutlimitation:

Adjacent refers to being positioned next to or adjoining or neighboring,or having a common vertex or common side. Thus, adjacent PV panels wouldinclude PV panels that have one side close to (from a few inches apartto abutting) and facing one side of another PV panel. Sometimes, but notalways, the corners of adjacent panels align; so four adjacent panelswould have one corner each that nearly or actually touch the other threecorners.

Adjustable refers to the capability of being changed so as to match orfit.

Adjustably connected refers to an object, item, mechanism, apparatus,combination, feature, link or the like that loosely, slidable, orrigidly links, interlocks, joins, unites or fastens two or more thingstogether in a manner that can be changed so as to match or fit.

Attach or attachment refers to one or more items, mechanisms, objects,things, structures or the like which are joined, fastened, secured,affixed or connected to another item, or the like in a permanent,removable, secured or non-permanent manner.

Axis of rotation refers to a center around which something rotates,sometimes considered a straight line through all fixed points of arotating rigid body around which all other points of the body move in acircular manner.

Beneath refers to extending or being situated directly or substantiallyunderneath, typically with close proximity or contact.

Between refers to being situated, located, or otherwise oriented at, in,or across the space separating two objects or regions.

Connect or connecting refers to loosely, slidably, or rigidly bringingtogether or into contact with or joining or fastening to form a link orassociation between two or more items, mechanisms, objects, things,structures or the like.

Connector refers to an object, item, mechanism, apparatus, combination,feature, link or the like that loosely, slidable, or rigidly links,interlocks, joins, unites or fastens two or more things together. Mayalso include a device, an object, item, mechanism, apparatus,combination, feature, link or the like for keeping two parts of anelectric or electronic circuit in contact.

Coplanar refers to the circumstance where two or more objects aresituated, located, or otherwise substantially oriented in the sameplane.

Couple refers to loosely, slidably, or rigidly joining, linking,interlocking, connecting or mating two or more objects or items,mechanisms, objects, things, structures or the like together.

Coupling refers to an object, item, mechanism, apparatus, combination,feature, link or the like that loosely, slidably, or rigidly joins,links, mates, interlocks, or connects two things together.

Crossbar refers to a mounting component that may be laterally applied toa component of combination of components that are mounted to a substrateor structure. Without limitation, a top arm or upper pedestal may be acrossbar.

Double male connector refers to a connector (see above) having two maleor insertable members, usually used for connecting two female orreceiving parts or coupling members together.

Disengage refers to detaching, freeing, loosening, extricating,separating or releasing from something that holds-fast, connects,couples or entangles. See Engagement below.

Enable refers to facilitating or making possible, able, feasible,practical, operational, or easy; or to cause to operate.

End refers to a final part, termination, extent or extremity of anobject, item, mechanism, apparatus, combination, feature, or the likethat has a length.

Engage refers to interlocking or meshing or more items, mechanisms,objects, things, structures or the like. See Disengage above.

Frame refers to an essentially rigid structure that surrounds orencloses a periphery of an item, object, mechanism, apparatus,combination, feature, or the like.

Freely refers to being without or exempt from substantial restriction orinterference by a given condition or circumstance. May also refer tobeing unobstructed, unconstrained, unrestricted or not being subject toexternal restraint.

Gap refers to a break, void, opening, cleft, breach, aperture,separation, or space, as well as an interruption of continuity, betweentwo objects, or within an object.

Groove refers to a long, narrow cut, rut, indentation, channel, furrow,gutter, slot or depression often used to guide motion or receive acorresponding ridge or tongue.

Height adjustable refers to change or adapt to bring items, objects,mechanisms, apparatus, combinations, features, components or the likeinto a proper, desired or preferred relationship of a distance orelevation above a recognized level, such as the ground or a supportsurface.

Insertable refers to an object, item, mechanism, apparatus, combination,feature, link or the like which is capable of being put in, enteredinto, set within, introduced, inset, inserted, placed, fit or thrustinto another an object, item, mechanism, apparatus, combination,feature, link or the like.

Integral with refers to being essential or necessary for completeness,constituent, completing, containing, entire, or forming a unit. May alsorefer to consisting or composed of parts that together constitute awhole.

Laminate or PV laminate refers to a photovoltaic device having aninterconnected assembly of solar cells, also known as photovoltaic cellswhich is frequently, but not always, laminated with glass and/or othermaterials.

Length refers to a measurement or extent of an object, item, mechanism,apparatus, combination, feature, link or the like from end to end,usually along the greater or longer of the two or three dimensions ofthe body; in distinction from breadth or width.

Located refers to where an object or a series of objects is physicallysituated with respect to one or more other objects.

Locked refers to fastened, secured or interlocked.

Orthogonally refers to relating to or composed of right angles,perpendicular or having perpendicular slopes or tangents at a point ofintersection.

Near refers to a short distance from an object or location.

Perimeter refers to an essentially continuous line forming the boundary,periphery or circuit of a closed geometric figure; the outer limits ofan area.

Photovoltaic module (sometimes referred to as a PV module, solar panel,solar module, or photovoltaic panel) refers to a packaged,interconnected assembly of solar cells, also known as photovoltaiccells, frequently, but not always, laminated with glass and othermaterials and sometimes surrounded by a frame. A plurality of PV modulesare commonly used to form a larger photovoltaic system referred to as aPV array (see below), to provide electricity for commercial, industrialand residential applications.

Pivotally refers to or relates to an object, item, mechanism, apparatus,combination, feature, link or the like serving as a pivot or the centralpoint, pin, shaft or contact on which another object, item, mechanism,apparatus, combination, feature, link or the like turns, swings, rotatesor oscillates.

Positionable refers to an object, item, mechanism, apparatus,combination, feature, link or the like which is capable of beingpositioned, placed or arranged in a particular place or way.

Preload refers to the force that must be overcome to separate a jointonce force is applied to attach a coupling to the joint. The appliedforce deforms the coupling and/or one or more of the components of thejoint and becomes the force that must be overcome to separate the joint.

PV laminate refers to a photovoltaic device having an interconnectedassembly of solar cells, also known as photovoltaic cells which isfrequently, but not always, laminated with glass and/or other materials.A PV laminate with an integral frame which may support the PV laminateis sometimes referred to as a PV module.

PV module refers to a photovoltaic module (sometimes referred to as asolar panel or photovoltaic panel) is a packaged interconnected assemblyof solar cells, also known as photovoltaic cells, frequently, but notalways, laminated with glass and other materials and sometimessurrounded by a frame. A plurality of PV modules are commonly used toform a larger photovoltaic system referred to as a PV array (see below),to provide electricity for commercial, industrial and residentialapplications.

PV array refers to a plurality of photovoltaic modules connectedtogether often in a pattern of rows and columns with module sides placedclose to or touching other modules.

Rail refers to refers to a relatively straight, usually essentiallyevenly shaped along its length, rod, beam, girder, profile or structuralmember or the like, or plurality of such, of essentially rigid materialused as a fastener, support, barrier, or structural or mechanicalmember.

Rail member refers to a structural entity, element or unit (or part ofsuch entity, element, or unit) that acts as or embodies a rail.

Removable refers to one or more items, mechanisms, objects, things,structures or the like which are capable of being removed, detached,dismounted from or taken-away from another item or the like, orcombination.

Rectilinear refers to one or more items, mechanisms, objects, things,structures or the like which are essentially bounded by, characterizedby or forming straight and substantially parallel lines.

Rigidly couples refers to joining, linking, connecting or mating two ormore objects or items, mechanisms, objects, things, components,structures or the like together in a non-flexible manner that isdifficult to bend or be forced out of shape.

Roof refers to a structure or protective covering that covers or formsthe upper covering or top of a building. The upper surface of a roof isoften used as a support surface for mounting, connecting or otherwiseattaching a PV module or a PV array.

Rotatably refers to one or more items, mechanisms, objects, things,structures or the like which are capable of being rotated, revolved orturned around or about an axis or center.

Skirt refers to an edging, molding or covering that may be fixed to theedge of a PV module to conceal or block the bottom area under a PV arraywhen the PV array is mounted to a support surface.

Span refers to an extent or measure of space between, or the distancebetween two points or extremities.

Support or supporting refers to one or more items, mechanisms, objects,things, structures or the like which are capable of bearing weight orother force, often to keep the item or the like from falling, sinking,slipping or otherwise moving out of a position.

Support structure refers to a structure, such as a roof, table or theground which may provide a base for securing PV modules to form a PVarray.

Threaded refers to one or more items, mechanisms, objects, things,structures or the like which have, embody or include an essentiallyhelical or spiral ridge or rib, as on a screw, nut, or bolt.

Various locations refer to places, positions or sites that are differentfrom one another, more than one, individual or separate.

Vertical height adjustment refers to change or adapt to bring items,mechanisms, objects, things, components, structures or the like orcomponents into a proper, desired or preferred relationship of adistance or elevation above a recognized level, such as the ground or asupport surface.

Width refers to the state, quality, or fact of being wide or ameasurement or extent of something from side to side; in distinctionfrom breadth or length.

FIG. 1 shows a perspective view of a leveling foot, such as levelingfoot 110, for coupling PV modules together and height-adjustablyattaching one or more PV modules to a mounting device or flashing mount(such as those described below and/or shown and disclosed in detail atU.S. patent application Ser. No. 13/673,985 entitled: “Solar PanelAttachment System”, filed approximately Nov. 9, 2012; which isincorporated by reference herein in its entirety) and then to astructure, such as a roof; or other support structure. Leveling foot 110may provide some of the same functions as other leveling feet describedin other patent applications of at least one common inventor or commonassignee, while also providing a number of novel features and functions.FIG. 2 shows a side view of leveling foot 110. FIG. 3 shows aperspective view looking from underneath leveling foot 110, and FIG. 4shows a section cut through the middle of leveling foot 110. FIG. 5shows a perspective view of a grounding clip 124. Throughout thefigures, like numerals refer to like structures or features.

Leveling foot 110 comprises a coupling for connecting adjacent PVmodules together, such as spring coupling 120. Spring coupling 120 maycomprise a key side 121 and a tongue side 122, each or either forconnecting to a groove (shown later) in a PV module frame as disclosedin other patents and patent applications of at least one common inventoror common assignee. In other embodiments spring coupling may wrap arounda PV module frame; also as described in other patent applications of atleast one common inventor or common assignee. Generally, key side 121may rotatably engage a frame and substantially resist movement of a PVmodule in the plane of the top of surface of a PV module. Tongue side122 may also rotatably engage a PV module frame, yet it may furtherallow for variable positioning along one axis in the plane of the top ofsurface of the PV module. Some novel features of the instant springcoupling 120 include, but are not limited to, upper jaw 187, which mayact at least partially as a spring under load; grounding clip 124, whichmay at least partially cut into the PV frame to create a grounding bond;and tail 123 and support 189, each or either of which may providesupport to a bottom side of a PV module frame. Leveling foot 110 mayfurther comprise a base 140, which may retain stud 130 and provide aslot 143 for a fastener that connects leveling foot 110 directly to asupport structure or to a flashing device or other mounting hardware.Each of these features and others will be described in more detailbelow.

Coupling 120 may also comprise a separate grounding clip 124 that may bemade, for example, from metal and may be installed primarily betweenupper and lower jaws 187, 188 as shown in FIGS. 1-5. FIG. 5 showsgrounding clip 124 in isolation from coupling 120 so that its featuresmay be better understood. Grounding clip 124 may be inserted, forexample at the factory or at a later time, from the left (as shown inFIG. 2) and pushed in the direction of the arrow until a tab 192 dropsinto a slot 193 on a top surface of lower jaw 188. Grounding clip 124may further comprise a top tab 127 with teeth 196 for scraping along abottom surface of upper jaw 187 to ensure a ground bond betweengrounding clip 124 and the main body of spring coupling 120. One or moregrounding teeth or edges 125 on key side 121 may cut into an upper lipor other portion of frame 104 a upon installation, and grounding teethor edges 126 may cut into a lower lip or other portion of frame 104 bupon installation. Thus, mechanical connection of modules 100 a and 100b to coupling 120, as described below, may further result inestablishment of a ground bond between frame 104 a and frame 104 b. Insome embodiments grounding edges 126 and 125 may also flex slightlyunder load in order to take up tolerance.

Base 140 of leveling foot 110 may comprise a retainer plate on a bottomside, such as retainer plate 147, may be held to base 140 via fasteners,rivets, screws, bolts, nails, or the like, such as rivets 141. Retainerplate 147 may be inset in a recess 146 in a bottom side of base 140 sothat base 140 may sit evenly upon a mounting surface. Stud 130 maycomprise a head 131 that is captured between retainer plate 147 and base140 and resists upward motion of stud under load. An optional discspring or resilient material such as rubber washer 132 may be capturedbetween stud head 131 and base 140 to take up tolerance and provide aconsistent and smooth feel while rotating stud 130. Base 140 may furthercomprise flanges 142 for widening a width of base 140 (for enhancedstrength) with minimum material consumption and cutouts 144 forconnecting other hardware, such as a lifter for raising a height ofmodules 100 a, 100 b. Base 140 may also comprise a cutout 145 forcapturing a string line that may be used to line up a row of levelingfeet 110 on a support structure.

Stud 130 may operate in a similar manner to leveling foot studs asdescribed in described in other patents or patent applications of atleast one common inventor or common assignee. For example, rotation ofstud 130 from the top via drive feature, such as hex drive feature 133,may allow height adjustability for coupling 120 (and thus modules 100 a,100 b). In other embodiments coupling 120 and base 140 are one piecewith no height adjustment mechanisms between them.

The discussion will now be expanded to include FIGS. 6-8 which showsection views through two PV modules 100 a and 100 b during theinstallation process as spring coupling 120 is utilized to connectmodules 100 a and 100 b together. The section cut is taken throughmodules 100 a, 100 b in a location just behind the outer flaps (labeled“KEY” and “TONGUE”) of grounding clip 124 (orthogonal frame members notshown for clarity). FIG. 6 shows module 100 a already connected tospring coupling 120 on key side 121. In a similar manner to the key sideof prior couplings described in other patents or patent applications ofat least one common inventor or common assignee, the key side is engagedwith a groove in the frame 104 a of module 100 a, such as groove 105 a,by inserting key side 121 at an angle, such as an angle between 5 and 75degrees (or commonly 5-20, 20-30, 30-50, 50-75, 5-25, 25-50, 50-75degrees), then rotating leveling foot 110 downward (clockwise as shownin FIG. 6) until the lowest point of hump 185 passes by point or edge103 a on a lip of groove 105 a. Hump 185 may be sized such that key side121 slightly pries open groove 105 a and/or upper and lower jaws 187,188 may flex closer together during the rotating engagement process,then after hump 185 passes point or edge 103 a, a spring force resultingfrom groove 103 a flexing open and/or upper jaw 187 flexing downwardtowards lower jaw 188 may cause key side 121 to snap into, rest stablywithin, or connect to frame 104 a.

One of skill in the art will recognize that the combination of groove105 a being able to spring open and jaws 187, 188 being able to springcloser together creates a double spring action that may provide animproved means and structure for taking up tolerance, such as may berequired when the dimensions of the mating parts vary slightly from thenominal dimensions. For example, if the width of groove 105 a has amanufacturing tolerance of ±0.020″ and the height of key side 121 has amanufacturing tolerance of ±0.010″, then without the spring action ofjaws 187, 188 the spring action of groove 105 a would need to have theability to spring open by up to 0.060″ in order to account for allpossible conditions within the tolerance bands given. While this may bepossible as long as the spring is very flexible (for example, when thespring rate is low), the spring force delivered by groove 105 a willincrease the further groove 105 a opens (as long as it is not pried openpast the point of plastic deformation), thereby increasing thedifficulty of installation with increasing interference between the twomating parts. Yet, since the lower jaw of groove 105 a must also providestructural support when uplift forces are present on module 100 a and/or100 b, a reasonably stiff spring may be required. Thus, this requirementfor a weak spring in order to make installation easy across the wholetolerance band is opposing the structural requirement for a stiff springin order to resist uplift. The instant disclosure at least partiallysolves this problem by including a second spring in the form of upperjaw 187 which may flex toward lower jaw 188 during installation in orderto provide additional tolerance take-up and effectively reduce theamount that groove 105 a has to spring open to connect to a given keyside 121. This reduction also improves the feel of the device duringinstallation (and eases installation) since the highest spring forcefrom groove 105 a is reduced. Furthermore, upper jaw spring 187 may notneed to resist significant uplift or downward forces due to presence oflower jaw 188 and support 189, thereby enabling upper jaw spring 187 tobe a relatively weak spring which may result in a more consistent feelwhen inserting key side 121 into grooves 105 a of varying width.

Catch 181 may resist horizontal movement of coupling 120 in groove 105 aand rib 182 may serve as a guide during installation. Duringinstallation, an installer may align rib 182 with an edge of groove 105a, then pivot coupling around a base of rib 182 to install.

With coupling 120 connected to module 100 a, a next installation stepmay typically include at least partial connection of leveling foot 110to a support structure or other hardware via a fastener, bolt, lagscrew, nail, pin, hook, stud, or the like, such as fastener 106. In someembodiments leveling foot 110 may be connected directly to a flashingdevice, such as one of the flashing devices described in U.S. patentapplication Ser. No. 13/673,985 entitled: “Solar Panel AttachmentSystem”, filed approximately Nov. 9, 2012. In other embodiments levelingfoot 110 may be connected directly to a roof or other support structuresuch as a ground mount rack, a rail, a profile, a beam, a wall, or aland/water/air/space vehicle, such as a boat. In still otherembodiments, as be described below, leveling foot 110 may be connectedto a tile flashing mount, or similar structure(s).

With module 100 a connected to a leveling foot and attached to a supportstructure (not shown), PV module 100 b may also be connected to coupling120. Module 100 b may be first placed on top of coupling 120 atapproximately 90 degrees (usually between 80-110 degrees) relative tomodule 100 a as shown in FIG. 6. Ribs 182 and 183 may provide a restingplace for a portion of frame 104 b. Subsequent rotation of module 100 bdown (clockwise), as shown in FIG. 7 by dashed lines at an intermediateposition and solid lines at a final position for module 100 b,demonstrates how a slot between rib 183 and upper catch 184 serves to atleast partially retain an upper lip of groove 105 b and thus help toguide module 100 b down and into the final position.

As shown in FIGS. 6-8, coupling 120 engages lower jaw 106 b of frame 104b in a pivot-fit action as module 100 b is rotated into position.Specifically, as module 100 b rotates approximately 2-30 degrees fromhorizontal, a bottom surface of frame 104 b may engage with and begin toroughly pivot on an edge 129 of tail 123. This pivoting action may forceedge 103 b upward and cause it to press against a bottom portion 190 oftongue side 122. Thus two offset bearing portions (lower portion 190 andedge 129) effectively connect coupling 120 to lower jaw 106 b of frame104 b. Offset bearing portions 190, 129 create a pivot-fit connection asunderstood in the art, and as shown and described in other patents orpatent applications of at least one common inventor or common assignee.The length of tongue portion (left to right in FIG. 6) is such that afinal position of module 100 b may be adjusted left to right to take uptolerances at the module level as an array of modules 100 are beingassembled. Lower bump or catch 186 serves to tighten the pivot-fitbetween coupling 120 and lower jaw 106 b as module 100 b is movedhorizontally, without rotating significantly out of plane with module100 a, such as when fully installed yet under a heavy wind load thatcauses uplift forces on module 100 b. Upper catch 184 may also act to atleast partially resist tongue side 122 from being pulled out, whilemodule 100 b is still approximately planar with module 100 a, bycontacting an inside surface of an upper lip of groove 105 b.

FIG. 8 shows a close-up of the circled region in FIG. 7. This figureshows how tail 123 may flex downward effectively lowering edge 129 andincreasing a vertical distance between bearing portions 190, 129 (thedashed lines indicate a nominal position of tail 123 prior toinstallation of module 100 b). Thus, tail 123 may spring open to take uptolerance. One of skill in the art will note that the spring rate ontongue side 122 may not need to be as low as on key side 121 since thespring on tongue side 122 is being opened by a lever arm consisting ofthe width (or length) of module 101 b, whereas the spring on key side121 is being opened by hand with substantially less leverage. Therefore,a double spring action may not be required on tongue side 122, thoughsome embodiments do comprise a double spring action on both sides.

Support 189 may provide support to module 100 a under heavy downwardloads. Since upper jaw 187 is a spring, heavy loads may push module 100a down slightly until it contacts support 189.

In other embodiments a distance between edge 129 and lower portion 190is increased such that the entire module frame 104 b is locked betweenthe bearing portions 190, 129 upon rotation. In other embodiments ahorizontal distance between edge 129 and lower portion 190 is increasedor decreased to change an optimum angle of insertion and/or to change anamount of interference between edge 103 b and lower portion 190 whenrotated down near zero degrees (module 100 b is shown as approximatelyplanar with module 100 a).

Coupling 120 may be constructed from extruded material such as aluminumor plastic, though other materials or composites are suitable as welland explicitly disclosed herein. Base 140 may be made from cast ormachined metal or plastic or other suitable materials or composites andare explicitly disclosed herein.

Some benefits of leveling foot 110 may include:

More consistent and smoother feel while connecting to a range ofdifferent groove 105 dimensions within a tolerance range thereof;

Improved installation process via provision of inclusion of variousribs, catches, and/or slots to guide coupling 120 into groove 105 aand/or groove 105 b into final engagement with coupling 120.

FIGS. 9-16 show an embodiment of a tile flashing mount 200. FIG. 9 showsa perspective view of a device for replacing a tile on a tile roof withhardware that connects to a support structure below and a PV moduleabove, such as tile flashing mount 200. FIG. 9 shows the x, y, and zaxes in the lower left corner. For purposes of this disclosure “up”,“vertical”, “above”, etc. shall reference or refer to the direction ofthe arrow along the z-axis, which is approximately perpendicular to theroof; “lateral”, “side-side”, etc. shall reference or refer to thedirection of the arrow (or its opposite) along the x-axis; and“up-roof”, “down-roof”, etc. shall reference or refer to the directionof the arrow (or its opposite) along the y-axis. The view in FIG. 9shows a tile at the edge of a roof being replaced by tile flashing mount200, yet it may replace any of, or multiples of, the tiles on a roofTypically, tile flashing mount 200 may be used to replace a tile that isover a rafter, purlin, or other structural member so that tile flashingmount may be attached to such structural member. FIG. 10 shows a sideview of tile flashing mount 200.

Tile flashing mount 200 may comprise: a rigid structural portion forresting on and connecting to a roof in the area where a tile has beenremoved, such as base 210; a relatively thin flashing portion formed tomate with surrounding tiles and base 210 and/or to shed water away fromthe inside of the building, such as flashing 220; and an upper portionfor receiving a PV module, coupling, connecting bracket, or levelingfoot and connecting to base 210 in a substantially water-tight or waterresistant manner, such as upper pedestal 230. Each of these elementswill be described in more detail below.

Referring to FIGS. 9-10 and with particular reference to FIG. 12, aperspective view of base 210 installed on a tile roof, base 210 maycomprise one or more flanges with a substantially flat bottom surface inthe x-y plane, such as flanges 215 a, 215 b. Flanges 215 a, 215 b mayfurther comprise holes, slots, grooves, indentations, or the like, suchas slots 217 a, 217 b for allowing a lag screw 211 to pass through andsecure base 210 to a rafter, purlin, beam, or the like, such as rafter204, or directly to roof sheathing material 205. Slots 217 a, 217 b areintentionally not shown running the entire length of flanges 215 a, 215b in order to leave a tail portion 219 a, 219 b for resisting upwardloads. For example, the distance between lag screw 211 and the end offlange 215 a may provide a resistive moment when a force (such as wind)effectively pulls upward on upper portion 216. Preventing lag screws 211from being inserted in close proximity to an end ensures that tailportion 219 a may provide significant resistive moment to counteractupward forces. This novel feature may eliminate or minimize the need foradditional screws elsewhere in base 210.

Base 210 may further comprise vertical portions 214 a, 214 b sized tobring upper portion 216 into mating relation with an underside of aflashing. Upper portion 216 may comprise holes 218 for receiving afastener 212. In some embodiments fastener 212 is a carriage bolt with asquare feature on the underside of the bolt head that may bepress-fitted or swaged into square-shaped holes 218, thereby enablingbase 210 to include integral fasteners when being deployed to or in thefield. In other embodiments holes 218 may be threaded. Flanges 215 a,215 b may be welded onto vertical portions 214 a, 214, or entire base210 may be a single unitary (for example, a cast or formed) piece. Otherembodiments contemplate other materials and methods of manufacturing aswill be understood by one of skill in the art.

One of skill in the art will recognize that base 210 may be variablypositioned within the space revealed when a standard tile is removed.For example, base 210 may be slid down-roof from the position shown inFIG. 10 to a position just above lower tile 201 b. Flanges 215 a, 215 bmay also be wide enough laterally to reach all or most rafter positionswithin the revealed space once upper portion 216 is aligned with thepeak of tile 201 a, as will be discussed in more detail below.

Expanding consideration to include FIG. 13, which is a perspective viewof flashing 220 and base 210 installed on a tile roof, flashing 220 ofthe instant embodiment may be manufactured as a formed piece of thinsheet metal or molded plastic and is generally shaped similar to thesurrounding tiles except for the thickness of the material(s). In someembodiments flashing 220 comprises rolled edges, is a hollow form of thesame thickness as a tile, or is molded as a solid piece of material ofthe same thickness as a tile. While flashing 220 comprises the sameapproximately “S” shape as the surrounding tile(s) in the regions whereflashing 220 mates therewith, flashing 220 further comprises a raisedand substantially flat portion, such as platform 224 with walls 222,that may be located inward from the mating edges and generallypositioned to align with upper portion 216 of base 210 such that upperportion 216 may fit at least partially inside of the cavity formed onthe underside of platform 224. Two pairs of holes 223 may be provided toreceive screws 212, thereby enabling base 210 to be located beneath theupper pair of holes 223 or the lower pair of holes 223. The underside ofplatform 224 may also comprise a means, method, apparatus or structurefor inhibiting or preventing water ingress through holes 223 in flashing220, such as rubber seal 221. In some embodiments holes 223 may furthercomprise adhered tabs or plugs, so that only the holes 223 that areneeded or actually utilized are uncovered or unplugged. As is typicalwith tiles, flashing 220 of the current embodiment may slip under tile201 a and over tiles 201 b and 201 c as shown in FIG. 13. An overlappingportion 225 may be provided for mating with tile 201 c. If there was afourth (4th) tile, as would be typical in a middle area of a roof,flashing 220 would at least partially slip under it. In this manner thestandard method of interleaving and channeling water, as is commonlyused for tiles, may not be interrupted, and may be assisted, by flashing220. Platform 224 is shown in FIG. 13 near tile 201 a, though otherembodiments contemplate location(s) of platform 224 further down-roofand closer to tile 201 b.

FIG. 10A shows a perspective view of flashing 220 with platform 224,overlapping portion 225 and side interleaving portion 226.

Expanding consideration to further include FIG. 14, a perspective viewof tile flashing mount 200 installed on a tile roof, upper pedestal 230is shown located above or on top of flashing 220 and connected to base210 via fasteners 212 and nuts 213. Tightening of nuts 213 may compressflashing 220 and seal 221 between upper pedestal 230 and base upperportion 216, securing the separate parts of tile flashing mount 200together and providing a tight seal to inhibit or prevent water ingressthrough holes 223. Risk of water intrusion though holes 223 is furtherminimized by the fact that platform 224 is raised above the rest offlashing 220 surface thereby resulting in walls 222 channeling wateraway from holes 223. As discussed above, upper pedestal 230 may beattached via either the upper or lower pair of holes 223, depending onthe location of base 210. Upper pedestal 230 may also be attachedrotated 180 (usually between 170 to 190) degrees from the orientationshown in FIG. 14, as will be discussed in more detail below.

Upper pedestal 230 may comprise a series of holes, such as holes 231,232, which may be threaded, or in other embodiments may bethrough-holes. As shown in FIG. 14, the present embodiment comprises tworows of holes 231, 232 running up-roof for the purpose of providingvarious connecting locations for a PV module, coupling, connectingbracket, rail, leveling foot, or the like. The row of holes 231 may beseparated by a lateral distance, such as 0.5 to 10 (often 0.5-2, 2-4,4-6, 6-10 or 1-5) inches, from holes 232 so that a conflict or blockagebetween a leveling foot and another device that connects to a PV moduleframe (such as an interlock as shown and described in other patents orpatent applications of at least one common inventor or common assignee)may be avoided, ameliorated or minimized. For example, if an interlockis located in groove 105 a on module 100 a in the same lateral positionas a desired position for leveling foot 110 (when connecting to hole231), then leveling foot 110 may be moved to the corresponding hole 232to avoid interference with the interlock. In other embodiments, one ormore holes 231, 232 may be replaced by slots. In still other embodimentsleveling foot 110 may snap, press-fit, lock, rotate, or slide onto upperpedestal 230 without requiring conventional fasteners.

Referring now more particularly to FIGS. 11-14, a series of installationsteps are shown or illustrated. FIG. 11 shows a typical, non-limitingtile roof 10 with tiles 201 hanging on battens 202. Battens are shown ontop of roof sheathing 205, such as plywood, Oriented Strand Board (OSB),or the like which may be supported by rafters 204 (centerline of raftershown as a single dotted line). Since the instant embodiment is adaptedfor installation approximately in the space of a single tile, one tileis shown removed from the leftmost column of tiles 201 (when lookingup-roof). Any tile in the array of tiles could have been removed, but aleftmost tile is shown as removed for greater visual clarity for thepurposes of this disclosure. Tiles 201 are shown here in a common “S”tile type, which is similar to a “Capistrano” tile made by Eagle RoofingProducts of Rialto Calif. In other embodiments tiles 201 are of a “W”tile type, which is similar to “Malibu” tiles made by Eagle RoofingProducts of Rialto, Calif. In still other embodiments tiles 201 are ofan essentially flat tile type, which is similar to “Ponderosa” tilesmade by Eagle Roofing Products of Rialto, Calif. In still otherembodiments tiles 201 are of other commonly available shapes and styles.With tile types not shown in the instant drawings, only minor changesare needed to the exact shape of flashing 220 in order to mate with thesurrounding tiles, as will be understood by one of skill in the art, andexplicitly contemplated and disclosed herein. Therefore, all generallyavailable tile types and geometries fall within the scope of the presentdisclosure.

FIG. 12 shows a first installation step after removing a tile 201. Base210 may be placed or located on sheathing 205, such that upper portion216 is approximately aligned with a peak 206 of tile 201 a and at leasta portion of slots 217 a, 217 b cross over rafter 204. If rafter 204 ison the other side of peak 206 than shown, the base 210 may be rotatedapproximately 180 degrees around the z-axis, at least partially tuckingflanges 215 a, 215 b under tile 201 c (battens may hold tiles above asheathing, so there is space in which to run or otherwise locate flanges215 a, 215 b).

Placement of a base along the y-axis may be determined in considerationof the other mounting hardware in the system. In the instant embodiment,a rail-free mounting system is shown, therefore tile flashing mount 200may be connected directly to leveling foot 110 (see below). This shouldprovide that there are a series of discrete points along the y-axis(approximately in the location of each seam between two PV modules 100and one each at the up-roof and down-roof edges of the PV array) whereeach leveling foot may be located. Tile flashing mount 200 isspecifically designed to make up for the lack of y-axis flexibilityinherent in a rail-free mounting system, as by including multiplemethods for positioning one or more components relative to each other:(a) base 110 may be located in the position shown in FIG. 12, orfurther, such as any location all the way down roof to just above tile210 b, (b) upper pedestal 230 may be connected to base 210 througheither the lower pair or upper pair of holes 223 in flashing 220 andthen oriented with elongated portion 233 facing either up-roof ordown-roof, and (c) leveling foot 110 may be connected to any one ofmultiple holes 231, 232 in upper pedestal. It should also be noted thatleveling foot base 140 may be rotated with respect to coupling 120, sobase 140 can swing up-roof and/or down-roof to align slot 143 with hole231, 232 and thus fine-tune its exact connection location. Therefore,the process of determining exactly where to place base 210 along they-axis may involve determining where, within the area of the removedtile, the edge of module 100 is likely to be, then placing base 210within a predetermined range of distances above or below that edge. Inother embodiments base 210 may be aligned with other features on thetile, such as the valley, edge, or other locations. In still otherembodiments there is no roof sheathing, but rather empty space,insulation, and/or non-structural material between rafters 204. In suchembodiments base 210 may be located or placed directly on rafter 204.Once the final position of base 210 has been determined, as discussedand described above, base 210 may be attached to rafter 204, as with lagscrews 211 (not shown in FIG. 12, see FIG. 10) or the like.

FIG. 13 shows an embodiment of the next step in the process ofinstalling tile flashing mount 200. Flashing 220 may be interleaved withthe surrounding tiles 201 a, 201 b, and 201 c, as by being tucked undertile 201 a along its up-roof edge and lapping over tiles 201 c and 201 balong its right lateral edge (looking up-roof) and down-roof edge.Platform 224 may be located or placed over upper portion 216 of base 210such that at least one, but usually two of holes 223 align with holesand/or pre-installed bolts 212 projecting upward from upper portion 216(bolts 212 not shown in FIG. 13, see FIG. 10).

FIG. 14 shows a final step in the installation of tile flashing mount200. Upper pedestal 230 may be positioned onto bolts 212 (see FIG. 10)and nuts 213 may be used to secure upper pedestal to base 210. Asdiscussed above, the orientation of upper pedestal may be determined inconsideration of the direction that elongated portion 233 will need toface (up-roof or down-roof) in order to result in at least one hole 231,232 aligning with slot 143 in leveling foot 110.

FIG. 15 is the a view similar to FIG. 14 except that base 210 has beenmoved down-roof and upper pedestal 230 has been rotated approximately180 degrees around or about the z-axis and connected to base 210 throughlower pair of holes 223 in flashing 220, and a leveling foot 110 hasbeen placed above or on-top of upper pedestal, in a position that alignswith at least one hole 231, 232 (bolt from foot to upper pedestal notshown).

FIG. 16 shows a perspective view of an alternate embodiment of an upperpedestal, upper pedestal 1630 which is similar to upper pedestal 230.Pedestal 1630 is similar to pedestal 230 except that it furthercomprises specially shaped slots that may allow pedestal 1630 to berapidly connected to base 210. The substantially cylindrical portions ofslots 1635, 1636 may be positioned and/or sized such that nuts 213 fitthrough slots 1635, 1636. Installation may be performed as follows, inthe following steps or procedures. Nuts 213 may be rotated such thatthere is a gap between nuts 213 and flashing 220 or such that a gapappears after pressing downward on flashing (due to seal 221compressing). Pedestal 1630 may then be located or placed above oron-top of flashing 220, such that nuts 213 pass through circularportions of at least one of slots 1635, 1636. Pedestal 1630 may then bepushed downward and rotated so that the shanks of bolts 212 move intothe skinnier portions of slots 1635, 1636. Release of downward pressurewill then cause seal 221 to expand, pushing flashing and pedestal 1630back up and into engagement with nuts 213. This embodiment has anadvantage of not requiring tools for the installation of the upperpedestal 1630.

FIGS. 17-18 show side and bottom views of upper pedestal 1630,respectively.

FIG. 19 shows a side view of base 1910, which is similar to base 210except it comprises a different embodiment for attaching to a roof.Flanges 215 a, 215 b of base 210 may be replaced by or with channels1915 a, 1915 b and hold-down brackets 1975 a, and 1975 b. Channels 1915a, 1915 b may be approximately the same length as flanges 215 a, 215 bbut they will commonly not contain any slots, thereby increasingstrength thereof. Hold-down brackets 1975 a, 1975 b may be only slightlywider than a head of lag screw 1911 and may be positioned substantiallyalong the whole length of channels 1915 a, 1915 b. Hold-down brackets1975 a, 1975 b may further comprise a hole for lag screws 1911 andsealing washers 1980 a, 1980 b.

FIG. 20 shows a perspective view of an embodiment of a tile flashingmount, such as tile flashing mount 2000. Tile flashing mount 2000 may besimilar to tile flashing mount 200 except that upper pedestal 230 may beeliminated and leveling foot 110 may connect directly to base 2210 viabolt 2212 and nut 2213. In other embodiments tile flashing mount 2000may comprise more or fewer holes 2223 for connection to leveling foot110.

FIGS. 21-32 show an embodiment of a tile flashing mount 2100. Tileflashing mount 2100 is similar to tile flashing mount 200 in that itcomprises a base, a flashing, and an upper pedestal and performs similarfunctions. However, the structural elements differ in certain ways asdescribed below. In general, tile flashing mount 2100 may provide fasterinstallation time relative to tile flashing mount 200, for example, dueto requiring fewer fasteners.

FIG. 21 shows a perspective view of tile flashing mount 2100 installedon tile roof 10 as described for a similar arrangement above. Tileflashing mount 2100 replaces the tile (located above) 201 b andinterleaves with the surrounding tiles similar to tile flashing mount200 described above. Tile flashing mount 2100 comprises a base 2110, aflashing 2120, and an upper pedestal, crossbar, or top arm 2130 as willbe described in more detail below. Leveling foot 110 is shown attachedto upper pedestal 2110.

FIG. 22 shows a side view of tile flashing mount 2100 installed on roof10. Upper pedestal 2130 has been shown as installed in a down-rooffacing direction, whereas FIG. 21 shows it in an up-roof facingdirection.

FIG. 29 shows a perspective view of tile flashing mount 2100 installedon roof 10. This view further reveals details of base 2110. Base 2110may comprise slotted or perforated flanges for attachment via lag screw2111, similar to mount 200. However, instead of an upper portion withholes 204, base 2110 comprises male features 2118 a, 2118 b for matingwith pedestal 2130 as will be described below.

FIG. 23 shows a perspective view of flashing 2120 with platform 2124 andwalls 2122. Flashing 2120 may be formed as a one-piece stamped or moldedpart. Walls 2122 comprise a waist portion 2123 that allows male features2118 a, 2118 b to snap up into the underside of platform 2124 duringinstallation. Since there are no required through-holes in flashing2120, the underside of platform 2120 may not require use of a seal asdescribed above for flashing 220.

FIGS. 24-27 provide different views of upper pedestal 2130: FIG. 24shows a perspective view, FIG. 25 shows a top view, FIG. 26 shows a sideview, FIG. 27 shows a bottom view, and FIG. 28 shows an end view. Upperpedestal 2130 may slide onto flashing 2120 and base 2110 duringinstallation, as by inserting platform 2124 into sliding pedestal 2130laterally. Pedestal 2130 may comprise a tapered slot, channel, groove,or the like, such as groove 2134. Groove 2134 may comprise tapered walls2135 a, 2135 b that enable a press-fitting action of pedestal 2130 as itis slid into place. Tapered walls 2135 a, 2135 b present a wider openingto groove 2134 at one end, thereby allowing pedestal 2130 to be easilystarted or otherwise positioned onto platform 2124 with little or nointerference. As force is applied laterally to slide pedestal 2130 intoposition, the interference may increases effectively, causing pedestal2130 to squeeze flashing 2120 around base 2110 to create a tight fitbetween all three components. In other embodiments tapered walls 2135 a,2135 b may be augmented or replaced with beveled, ribbed, toothed, orthe like portions. It should be noted that solar panels do not typicallyprovide very large loads to mounting hardware in the lateral direction,except during an earthquake, so pedestal 2130 is unlikely to slide backoff once installed in a solar array. In some embodiments pedestals 2130may be installed in opposite directions within the PV array therebypreventing lateral slippage even under significant lateral loads.Pedestal 2130 is shown as only comprising a single row of holes 2131(instead of two rows as with pedestal 230) since pedestal 2130 may bevariably positioned laterally, thereby still enabling conflicts betweenother frame-connecting components and leveling foot 110 to be resolvedby sliding pedestal 2130 along the x-axis. Variations, such as apedestal of the pedestal 2130 variety with more than one row of holes,and the pedestal 230 variety with only one row of holes, is herebydisclosed.

FIGS. 29-32 show a perspective view of a typical, non-limitinginstallation sequence for tile flashing mount 2100. FIG. 29 shows roof10 with base 2110 connected to rafters via lag screws 2111. Positioningof base 2110 is similar to base 210. FIG. 30 shows the next step whereflashing 2120 has been snapped onto base 2110. FIG. 31 shows pedestal2130 having been slid into position in the direction of the arrow. FIG.32 shows the final step of connecting leveling foot to pedestal 2130with bolt 2138.

FIGS. 33-39 show an embodiment of a tile flashing mount 3300. Tileflashing mount 3300 is similar to tile flashing mount 200 in that itcomprises a base, a flashing, and an upper pedestal and performs similarfunctions. However, certain structural elements differ in various waysas described below. In general, tile flashing mount 3300 may provideincreased lateral flexibility relative to tile flashing mount 200 due toa rotating design.

FIG. 33 shows a perspective view of tile flashing mount 3300 installedon tile roof 10 as described above. Tile flashing mount 3300 replacesthe tile above 201 b and interleaves with the surrounding tiles similarto tile flashing mount 200 above. Tile flashing mount 3300 comprises abase 3310, a flashing 3320, and an upper pedestal 3330 as will bedescribed in more detail below. Leveling foot 110 is shown attached toupper pedestal 3330 and upper pedestal 3330 is shown rotatedapproximately 30 (usually between 10-50, 15-45, or 25-35) degreesclockwise from the fully up-roof position.

FIG. 34 shows a side view of tile flashing mount 3300 installed on roof10 (for clarity, dashed lines are only shown where base 3310 is hiddenby flashing 3320 and where flashing 3320 is hidden by pedestal 3330;other hidden portions are not revealed with dashed lines). Withadditional reference to FIG. 36, which shows a perspective view of tileflashing mount 3300 installed on roof 10, further details of base 3310will be discussed below. Base 3310 may comprise slotted or perforatedflanges for attachment via lag screw 3311, similar to mount 200.However, instead of vertical portions 214 a, 2214 b, base 3310 maycomprise a cone-shaped riser portion 3314 with a male hexagonal portion3316 for mating with a corresponding female hexagonal portion on theinside of pedestal 3330, as will be described below in greater detail.Hexagonal portion 3316 may further comprise a threaded hole 3318 forreceiving a fastener.

FIG. 34A shows a perspective view of pedestal 3330 looking from theunderside. Pedestal 3330 may comprise a female conical portion 3336 formating with riser portion 3314 and aperture 3322 and a female hexagonalportion 3335 for mating with male hexagonal portion 3316. Pedestal 3320may further comprise a through-hole 3337 for receiving bolt 3312 and ahole 3338 which may be tapped for receiving a threaded bolt or athrough-hole for receiving a bolt that is secured by other means such asa nut.

FIG. 35 shows a perspective view of flashing 3320 with conical aperture3322. Flashing 3320 may be formed as a one-piece stamped or molded part.Aperture 3322 may be sized to slide over and mate with riser portion3314 during installation. Instead of a resilient seal as described abovefor flashing 220, aperture 3322 may be at least partially sealed bycompression, when female conical portion 3336 located on the inside ofpedestal 3320 may be pulled downward by tightening of bolt 3312. Theheight of the walls of aperture 3322 may also channel water away fromaperture 3322.

FIGS. 36-39 show a perspective view of a typical, non-limitinginstallation sequence for tile flashing mount 3300. FIG. 36 shows roof10 with base 3310 that is conical, substantially conical, or conicalwith one or more deviations connected to rafters via lag screws 3311.Positioning of base 3310 is similar to base 210. FIG. 37 shows the nextstep where flashing 3320 has been slipped over base 3310, conicalaperture 3322 walls are shown mating with the upper portion of riser3314 and male hexagonal portion 3316 is left protruding above thesurface of flashing 3320. FIG. 38 shows pedestal 3330 having beenslipped over both the walls of aperture 3322 and riser portion 3314,rotated to align female hexagonal portion 3335 with male hexagonalportion 3316, and then secured with bolt 3312. FIG. 39 shows the finalstep of connecting leveling foot 110 to pedestal 3330 with bolt 3338.

The six available rotational positions allowed by the hexagonalengagement of pedestal 3330 provides increased mounting flexibilityalong the x-axis. In some cases, for example where a rafter is locatednear the seam between two tiles, this flexibility may allow theconnection of a leveling foot closer to the rafter, thereby reducing thelength of a horizontal moment arm acting on lag screw 3311 under load.In other embodiments more or less rotational positions are available bychanging the number of sides from hexagonal (6) to pentagonal (5),octagonal (8), and other numbers of sides and/or using small teeth. Instill other embodiments essentially infinite rotational positions areenabled by relying on clamping force and friction resulting fromtightening of bolt 3312 to prevent rotation of pedestal 3330 under load.

FIGS. 40-45 show an embodiment of a tile flashing mount 4000. Tileflashing mount 4000 is similar to tile flashing mount 200 in that itcomprises a base, a flashing and performs similar functions. However,the structural elements may differ as described below. In general, tileflashing mount 4000 is simpler in that it does not comprise an upperpedestal 230, but rather achieves similar functionality by, among otherthings, increasing the size and raising the height of the flashingplatform and increasing the size of the upper portion on the base.

Flashing mount 4000 replaces the tile above 201 b and interleaves withthe surrounding tiles in a manner similar to the description for tileflashing mount 200 above. Tile flashing mount 4000 comprises a base 4010and a flashing 4020 as will be described in more detail below.

FIG. 40 shows a perspective view of base 4010 installed on tile roof 10.Base 4010 may comprise: a lower portion 4015 having generally flat shapewith optional stiffening ribs 4019 and slots 4017 a, 4017 b, . . . ,4017 c for lag screws 4011; a vertical riser portion 4014 with optionalstiffening ribs; and an upper portion 4016 having a generally flat shapeand comprising holes 4031, 4032. Since there is no upper pedestaldisclosed in the instant embodiment, upper portion 4016 may furthercomprise a cantilevered portion 4033 for providing connecting pointslocated out over or above the tile below. Such additional connectingpoints may be required in a rail-free mounting system where it isdesirable to always have a connecting point near each laterally runningPV module 100 edge.

FIGS. 41-42 show perspective views of flashing 4020 with sealing covers4028 covering holes 4023 (see FIG. 44). Sealing covers 4028 may comprisea semi-rigid sheet with a tab portion 4029 and an adhesive on theunderside (not shown). Covers 4028 may be factory-adhered, permittingthe installer (in the field) to utilize tab portion 4029 to remove asingle cover 4028 (or more covers) required for any or each specifichole that may be utilized for connection. In other embodiments, devicesor structures other than or in combination with tabs may be employed orused to enable easy removal of cover 4028, such as slots, ridges, bumps,handles, grips and other mechanisms which may be easily actuated by handor with a hand-held tool. In still other embodiments, covers 4028 maycomprise a plastic or rubber plug for easy removal and a fluid-tightseal. Walls 4022 rise upward towards platform 4024, which is larger thanplatform 224 since there is no upper pedestal in this embodiment.

FIGS. 40, 43, 44, 45 shows a perspective view of a typical, non-limitinginstallation sequence for tile flashing mount 4000. FIG. 40 shows roof10 with base 4010 connected to rafters via lag screws 4011. Positioningof base 4010 is similar to base 210. FIG. 43 shows the next step whereflashing 4020 has been slipped over base 4010. In some embodiments, abolt protruding skyward, such as a carriage bolt, may be installed inbase 4010 prior to installing flashing 4020, thereby making it easy todetermine which hole 4028 in flashing 4020 will be used. FIG. 44 showsflashing 4020 with one cover 4028 removed and ready for a fastener (notshown) to be installed through hole 4023. FIG. 45 shows the final stepof connecting leveling foot 4510 to base 4010 with bolt 4038. Levelingfoot 4510 is similar to leveling foot 110 except that it is longer,which may provide more mounting positions along the x-axis.

FIGS. 46-52 show an embodiment of a tile flashing mount 4600. Tileflashing mount 4600 is similar to tile flashing mount 200 in that itcomprises a base, a flashing, and an upper pedestal and performs similarfunctions. However, the structural elements differ in certain ways asdescribed below. In general, tile flashing mount 4600 provides thepotential to reduce uplift moments more than with other embodimentsdisclosed above, as will be described below.

FIG. 46 shows a side view of tile flashing mount 4600. Tile flashingmount 4600 replaces the tile above 201 b and interleaves with thesurrounding tiles similar to tile flashing mount 200 above. Tileflashing mount 4600 comprises a base or lower arm 4610, a flashing 4620,and an upper arm or pedestal 4630. Lower and upper arms 4610 and 4630may be identical parts or similar in construction. Lower arm 4610 mayfurther comprise hold-down clamps 4675 a, 4675 b for receiving lagscrews 4611 and clamping lower arm 4610 to roof 10. A cylindrical (orother cross-sectionally shaped elongated member) pipe or rod may connectbetween lower arm 4610 and upper arm 4630, such as pipe 4614. Pipe 4614may be externally threaded at one or both ends. Lower and upper arms4610 and 4630 respectively may each comprise a threaded hole ofapproximately the same size as pipe threads on pipe 4614 and areconnected to pipe 4614 by threading onto pipe 4614 then securing withretaining nuts 4613 a, 4613 b. In some embodiments, nuts 4613 a, 4613 bmay comprise cutting teeth or protrusions that cut in lower and upperarms respectively, thereby creating a reliable ground bond therebetween. In other embodiments pipe 4614 is not threaded but rathercomprises a retaining ring or protrusion in combination with a nut forcoupling arms 4610 and 4630 to pipe 4614. In still other embodimentspipe 4614 and arms 4610, 4630 may mate via tapered or splined features,or by a sleeve fitting, or by other means known to one of skill in theart. Arms 4610 and 4630 may be cast, extruded, molded, or otherwisefashioned metal, plastic, composite, or other reasonably rigid material.

FIG. 47 shows a perspective view of flashing 4620 with conical aperture4622. Flashing 4620 may be formed as a one-piece stamped or molded orotherwise formed part. Aperture 4622 may be sized to slide over pipe4614 during installation. Aperture 4622 may substantially prevent orinhibit water ingress through flashing 4620 via the height of its walls(which channel water away) and/or by a seal such as rubber, caulk,sealant, or the like (not shown) between pipe 4614 and aperture 4622.

FIG. 48 shows a perspective view from the underside of upper arm 4630with leveling foot 110 installed thereto. Upper arm 4630 may comprisetwo extensions projecting away from pipe 4614, such as L-shapedextensions 4679 a, 4679 b. Extensions 4679 a, 4679 b may be separated bya slot or gap as shown and a nut portion 4678 may be partiallypositioned within the gap to help resist torque loads applied to nut4678. Nut portion 4678 may further comprise upturned portions 1981 tofurther resist torque loads on nut portion 4678. Extensions 4679 a, 4679b may provide a channel for resting leveling foot 110 duringinstallation before leveling foot 110 is fully secured to upper arm4630. In other embodiments upper arm 4630 comprises a T-shaped slot forcapturing the head of a standard bolt or nut thereby eliminating theneed for a more custom nut, such as nut portion 4678. In still otherembodiments leveling foot 110 may be connected to upper arm 4630 by aset screw, clamping mechanism, press-fit, snap-on, or other means ofconnection. In still other embodiments PV module 100 may rest directlyon upper arm 4630 and may be clamped thereto without the need orrequirement for a leveling foot. In such embodiments the levelingfunctionality provided by a leveling foot may instead be handled byupper arm 4630, which may be variably positioned on pipe 4614, as byrotating and moving up and down the threaded portion thereof. Additionalleveling functionality may also be provided by adjusting the height ofpipe 4614 relative to lower arm 4610 via the lower threads on pipe 4614.

FIGS. 49-52 show a perspective view of a typical, non-limitinginstallation sequence for tile flashing mount 4600. FIG. 49 shows roof10 with base 4610 connected to rafters via lag screws 4611 runningthrough hold-down clamps 4675 a, 4675 b. Since lower arm 4610 and/orupper arm 4630 may rotate relative to pipe 4614, aperture 4622 inflashing 4620 may be positioned so that it may be aligned in its finalposition approximately with the centerline between the lower edge oftile 201 a and the upper edge of tile 201 b. With this alignment scheme,a first installation step may be to remove a tile and install lower arm4610 so that pipe 4614 will approximately line-up along the x-axis witha peak 206 of tile 201 a and will be approximately centered betweentiles 201 a and 201 b along the y-axis. Extensions 4699 a, 4699 b mayrun approximately parallel to the x-axis, as shown in FIG. 49, in orderto minimize the distance required to reach a rafter (which could existanywhere in the space between two tiles). However, in order to minimizemoments around the x-axis, lower arm 4610 may be rotated eitherclockwise or counterclockwise from the orientation shown in order to endup falling or otherwise being located essentially beneath the finallocation of leveling foot 110, as will be discussed further below. Itshould also be noted that hold-down clamps 4675 a, 4675 b may bepositioned anywhere along the length of lower arm 4610, including theregion beside pipe 4614, enabling connection to a rafter even if itfalls beneath or below pipe 4614.

FIG. 50 shows the next step where flashing 4620 has been slipped overbase 4610. In some embodiments the space between aperture 4622 and pipe4614 may be sealed with caulk or sealant or the like (not shown) at thisstage; in other embodiments this seal may be obtained by an integralrubber (or other suitable) seal in aperture 4622 as is common in theart.

FIG. 51 shows upper arm 4630 having been threaded onto pipe 4614 andfurther secured by retaining nut 4613 b. Nut 4613 b is shown here as atypical hexagonal nut, though in other embodiments a nut may compriseother shapes, such as square, pentagonal, octagonal, and the like, ormay be knurled so that it may be easily rotated by hand, or may comprisenotches so that it may be rotated by tapping, nudging, torqueing, orsimilarly applying force to the notches. Upper arm 4630 in the instantembodiment is shown as rotated around pipe 4614 until it reaches both adesired height off of (above) roof 10 and is at a desired rotationalposition, such as a position that would allow optimum placement ofleveling foot 110 relative to PV module 100 and to lag screws 4611. Oncethe desired height and/or rotational position have been achieved,retaining nut 4613 b may be tightened to resist further rotation ofupper arm around pipe 4614.

As a non-limiting example, an installer may determine that an edge of aPV module 100 will approximately align (once installed) with the linemarked 4609 in FIG. 49. Since leveling foot 110 may be variablypositioned along module frame 104 with respect to the x-axis, apreferred rotational position for upper arm 4630 may be in a positionthat results in leveling foot 110 being substantially close to positionA (in FIG. 49). Position A may be preferred since this would placeleveling foot 110 directly over rafter 4604, substantially reducing oreliminating a moment about the y-axis that would result in a pryingforce (during uplift) at lag screw 4611, if leveling foot 110 waspositioned to the right of A (as in FIG. 49). One of skill in the artwill recognize that the ability of upper arm 4630 to rotate around orabout pipe 4614, for example, in order to reduce or eliminate pryingforces on lag screws 4611, may reduce the cost and/or simplify theinstallation of tile flashing mount 4600.

FIG. 52 shows the step of placing leveling foot 110 onto upper arm 4630.Though PV module 100 a is not shown here for clarity, leveling foot 110may typically be connected to module 100 a first and then the assemblyof module 100 a and leveling foot 110 may be lowered down such thatleveling foot 110 rests within extensions 4679 a, 4679 b (as shown inmore detail in FIG. 48). Extensions 4679 a, 4679 b may temporarily holdor retain leveling foot 110 until leveling foot 10 is further securedvia nut portion 4678.

Upper and lower arms may be manufactured from ductile iron casting,though other methods such as aluminum, steel, other metals, plastics,composites and the like formed by casting, extruding, molding,machining, and the like may be suitable.

FIGS. 53-56 describe an embodiment of a shingle flashing mount suitablefor use when mounting PV module arrays to shingle roofs.

FIG. 53 shows a perspective view of a shingle flashing mount, such asshingle flashing mount 5300. Shingle flashing mount 5300 may comprise asubstantially thin, flat plate for interleaving with shingles, such asflashing 5310; a cylindrical (or other cross-sectionally shapedelongated member), externally threaded block or base, such as base 5320;and an internally threaded upper portion for threading onto base 5320and supporting a PV module, such as pedestal 5330.

Expanding the discussion to include FIG. 54, which provides a sectionview along line A-A, further details of flashing mount 5300 aredisclosed. Flashing 5310 may comprise raised platform 5315 comprisinghole 5317 centered on centerline 5380 and raised anti-rotation bumps5312.

Base 5320 may comprise anti-rotation notches 5322 for aligning withbumps 5312 in order to prevent rotation of base 5320 relative toflashing 5310 during installation, as will be described below. Base 5320may further comprise a centered hole 5228 and counter-bore 5227 forreceiving a lag screw (not shown) and a rubber seal 5334 positioned atleast partially within hole 5228 and comprising a lower portion 5335 forsealing engagement between a lower surface 5323 of base 5320 andplatform 5315 when base 5320 is tightened down against flashing 5310, asvia a lag screw through base 5320 and into a support structure below.The outside of base 5320 may comprise threads 5321 for receiving and/orconnecting to pedestal 5330 in a height adjustable manner.

Pedestal 5330 may comprise a lower portion 5332 comprising internalthreads 5331 for threading onto base 5320. Pedestal 5330 may furthercomprise a substantially flat platform 5335 that at least partiallycantilevers beyond lower portion 5332 and may be adapted to support a PVmodule, such as PV module 1000.

FIGS. 55-56 show a perspective view of shingle flashing mount 5300connected to a PV module, such as PV module 1000. The steps to mount PVmodule 1000 with shingle flashing mount 5300 may be as follows. Theinstaller first may determine where the ultimate point of structuralconnection (such as a rafter) is located, then positions flashing 5300partially underneath such shingle, or shingles, such that hole 5317approximately aligns with the rafter and an edge of PV module 1000 to besupported by flashing 5300. A hole, down through rafter directlyunderneath hole 5317, may be optionally drilled at this time if thestructure below requires a pre-drilled hole. Next base 5320 is placed ontop of flashing, so that hole 5228 approximately aligns with hole 5317and anti-rotation notches 5322 approximately align with bumps 5312. Alag screw (not shown) may then be screwed through base 5320 and flashing5310, and into the structure below. Next pedestal 5330 may be threadedonto base 5320 until a desired height for PV module 1000 is reached.Pedestal 5330 may be maintained or left in a rotational position thatresults in at least one side of platform 5335 running approximatelyperpendicular to the engaging side of PV module 1000. The previous stepmay not be required if limited adjustability in the direction normal tomodule 1000 frame is permitted. With platform 5335 rotated to thedesired height, the next step is to place PV module 1000 on top of orabove platform 5335, as shown in FIGS. 55-56, such that an edge of PVmodule 1000 falls somewhere onto or above platform 5335. The finalmounting step may be to secure PV module 1000 to a cantilevered edge ofplatform 5335 with a clamping device, such as clip 5610, as will bedescribed in more detail below.

Clip 5610 may be a bracket, spring clip, “dream clip”, lock, spring armdevice, spring bracket, pivot-lock clip, lever clamp, lever clip, and/orsimilar to other clips disclosed and shown in U.S. Provisional PatentApplication No. 61/656,240 entitled “Rail Mounted PV Apparatus, Methodand System” filed approximately Jun. 6, 2012 and No. 61/698,292 entitled“Module Attachment System and Module Support System”, each of which isincorporated by reference herein in its entirety. Clip 5610 may beinstalled and/or operate as follows. First, clip 5610 may be orientedapproximately as shown in dashed lines in FIG. 56, then clip 5610 may bemoved toward PV module 1000, inserting upper lip 5611 into groove 1005while lower lip 5612 is positioned underneath a cantilevered portion ofplatform 5335. In some embodiments PV module 1000 does not comprise aside groove 1005, so upper lip 5611 may be located or moved into aposition just above the top surface of frame member 1004 in this step.Once clip 5610 is located in the position shown by dashed lines, clip5610 may be then rotated in the direction of the arrow until tab 5613aligns with an opening of groove 1005 or is located just below frame1004. However, before reaching this position, it should be noted thatlip 5611 may begin to engage with frame 1004 and lip 5612 may begin toengage with underside of platform 5335, thereby resulting in a bendingof spring arm 5614 as rotation continues. Once tab 5613 is low enough,it may be pushed or otherwise located in the direction towards frame1004 until tab 5613 is located at least partially in groove 1005 or atleast partially under frame 1004, then clip 5610 may be released. Theaction of releasing clip 5610 may result in tab 5613 exerting a springforce in a direction approximately opposite the arrow and effectivelyresulting in clip 5610 resting in a stabilized state due to beingengaged with frame 1004. In some embodiments lips 5611 and 5612 may becut into frame 1004 and platform 5335 respectively, thereby creating aground bond connection between frame 1004 and platform 5335.

In other embodiments a shingle flashing mount is not height-adjustableand therefore integrates the cantilevered platform portion into base5320, eliminating platform 5330 as a separate piece. In still otherembodiments additional slots, channels, grooves, or the like are addedto platform 5335 to enhance the engagement of clip 5610.

FIGS. 57-59 disclose an embodiment of metal roof mount 5700. Metal roofmount 5700 may comprise a base 5710 and a sealing layer 5712. A topsurface 5718 of base 5710 may comprise a series of channels 5719 forrecessing the heads of sheet metal screws 5713 which may be insertedthrough holes 5717 located within channels 5719. Top surface 5718 maycomprise a threaded hole 5716 for receiving a bolt, such as bolt 5720that may be used to attach a leveling foot 5770 to base 5710. Sheetmetal screws 5713 may be screwed through holes 5717 and into a raisedportion 21 of a sheet metal roof, such as trapezoidal metal roof 20.Sealing layer 5712 may at partially prevent water ingress through holescreated in metal roof 20 for sheet metal screws 5713.

An installation sequence for metal roof mount 5700 may go as follows.First, metal roof mount 5700 is screwed to metal roof 20 via screws 5713in locations that approximately line up with where the edges of PVmodules will be, taking care to install screws 5713 on raised portions.Next, as PV modules are being installed, leveling feet 5770 are attachedto PV modules via couplings 5776, and then connected to base 5710 viabolts 5720 threading into holes 5716. Bolts may further comprise lockwashers 5721 and washers 5722. An advantage of metal roof mount 5700 maybe that such enables installation of PV modules onto trapezoidal metalroofs without requiring the use of rails.

FIG. 59 discloses a metal roof mount 5700 being used with leveling foot110 as discussed above.

FIGS. 60-64 show an embodiment of a tile flashing mount 6000 that issimilar to tile flashing mount 4600, as shown in FIGS. 46-52, exceptthere are some minor changes in order to allow upper arm to receive abracket, spring clip, clamp, “dream clip”, lock, spring arm device,spring bracket, pivot-lock clip, lever clamp, lever clip, or clipsimilar to clip 5610, such as clip 6098. Changes to upper arm 4630,shown in the instant embodiment as upper arm 6030, may include: flippingupper arm 4630 over so that the vertical walls project downward insteadof upward, positioning nut 4613 b, shown here as nut 6013 b, underneathupper arm 4630 instead of on top of it, and providing a number of holes6031, 6032 along extensions 6079 a, 6079 b for receiving clip 6098.

FIG. 60 provides a perspective view of tile flashing mount 6000installed on tile roof 10 and connected to PV module 1000 via clip 6098.FIG. 61 shows a side view of the same installation shown in FIG. 60.Clip 6098 operates in a similar manner to clip 5610 and thus it may actby clamping PV module frame 1004 to another surface located beneathmodule frame 1004. And since this clamping action requires clip 6098 toapply a force to the underside of the surface beneath frame 1004, theflipping over of upper arm, as discussed above, enables a reasonablyflat surface, upward facing surface of extensions 6079 a, 6079 b, to bepositioned beneath an edge of frame 1004 for engagement with clip 6098.The provision of holes 6031, 6032 allows for easy insertion of clip 6098in different places along extensions 6079 a, 6079 b since the edge offrame 1004 may cross upper arm 6030 in different places depending onwhere module 1000 is located relative to pipe 6014.

Clip 6098, as shown in FIG. 60, operates in a very similar manner to thelever clip of our Application No. 61/698,292 (the “292 application”).See clip 302 in FIG. 5 of the '292 application wherein a PV module frameand a relatively flat plate (in the location of the lever clip) areclamped by an upper catch engaging the frame and a lower portionengaging beneath the plate (a corner support 302 or wind diffusor 303 inthe '292 application) by a rotating action of the lever clip and then alocking of the clip to the frame via a catch near the end of a bendingspring arm. Clip 6098 is shown in FIG. 60 fully installed and thebending of spring arm 6096 is viewable here.

FIGS. 62-64 show top views perpendicular to a plane of roof 10 depictingvarious installation configurations for tile flashing mount 6000. FIGS.62-64 show roof 10 as in previous figures, except that the position ofrafter 6004 (indicated by dashed line) beneath sheathing 205 is in adifferent location than rafter 204. As discussed above, it may bedesired to reduce a prying moment on lag screws that are installed intorafter 6004 (not visible in these two figures since they are beneathtiles 201). FIGS. 62-63 demonstrate how a reduction in prying moment maybe accomplished. In both FIGS. 62 and 63, PV module 1000, lower arm6010, and pipe 6014 are in approximately the same location. However, inFIG. 62 upper arm is positioned such that extensions 6079 a, 6079 b areextending in a direction that is more down-roof than in FIG. 63 and clip6098 is connected to module 1000 in different locations relative to thex-axis. More specifically, clip 6098 in FIG. 62 connects PV module 1000to upper arm 6030 at approximately line 6097. Whereas, in FIG. 63 clip6098 connects PV module 1000 to upper arm 6030 at approximately line6004 which is approximately directly over the lag screws 6011 (notvisible in FIG. 63, but connecting lower arm 6010 to rafter 6004 beneathtile 201 at line 6004). It is therefore clear in FIG. 62 that a momentabout the y-axis that may result from an upward force on module 1000(which translates into an upward force on clip 6098 at line 6097) may bedescribed as the distance B since the x-axis position of lag screw 6011may act as the center of rotation about the y-axis. The moment B may bedescribed as a prying moment since upward forces acting on this momentmay result in a prying action on lag screw 6011 that effectively pullsupward on screw 6011 when upward loads are applied to PV module 1000. InFIG. 63 the same upward force on module 1000 would result in a momentabout the y-axis of approximately zero since the force is being appliedsubstantially directly above the center of rotation about the y-axis. Itis therefore clear that rotation of upper arm 6030 from the positionshown in FIG. 62 to the position shown in FIG. 63, and a correspondingrepositioning of clip 6098, may result in the reduction of at least onemoment acting on lag screw 6011. One skilled in the art will recognizethat other embodiments described herein may reduce prying moments in asimilar manner.

Holes 6031, 6032 may be laid out in different locations on extensions6079 a, 6079 b. For example, the configuration shown in FIGS. 60-64 hasholes 6031 offset from holes 6032 along the length of extensions 6079 a,6079 b. This layout may allow clip 6098 to be located closer to rafter6004 in certain conditions. For example, the exact x-axis position ofclip 6098 along frame 1004 is determined by where the hole selected forconnection intersects with the edge of frame 1004; and in the holelayout shown the x-axis position of clip 6098 will be different if aspecific hole 6031 is chosen instead of the nearest hole 6032. Thisdifference along the x-axis results in more possible positions and thusthe opportunity to connect clip 6098 closer to a desired location abovea rafter than if less choices were available. In other embodiments otherhole layouts are provided.

FIG. 64 shows a similar configuration to that of FIG. 63 except module1000 has been moved up-roof to a location above, and covering, pipe6014. Upper arm 6030 has been rotated counterclockwise from the positionshown in FIG. 63, demonstrating that even with a new position of module1000, upper arm 6030 may be positioned such that clip 6098 isconnectable to frame 1004 approximately above rafter 6004.

FIG. 64 also demonstrates how tile flashing mount 6000, as well as tileflashing mounts 200, 2000, 2100, 3300, 4000, and 4600, provides theability to connect to an edge of a PV module substantially anywhere thatit may fall along the y-axis of a tile roof without requiring the use ofrails that span between connection points, as is common in the art. Inpractice, an installer may first determine, for a given installation,where the edge of each PV module will be relative to the roof. Theinstaller may then choose to remove specific tiles from the roof thatfall beneath the module edges, and then replace the removed tiles withtile flashing mounts according to the instant disclosure. With all tileflashing mounts installed, the installer may then connect PV modules tothe tile flashing mounts via leveling feet, clips, brackets, etc., asdescribed herein; again without running expensive rails between tileflashing mounts.

FIG. 65 shows an embodiment of a tile flashing mount 6500 that issimilar to tile flashing mount 200, as described in FIGS. 9-16, exceptthat the upper pedestal may be rotated relative to the base to providebetter x-axis flexibility and in some cases to allow a lower cost meansto enable the reduction of a prying moment on lag screws as discussedabove. Upper pedestal 6530 is shown with multiple holes 6535 forreceiving bolts 6512 that may secure upper pedestal to base via nuts orthe like (nuts not shown). A flashing, similar to flashing 220, thatwould be placed between upper pedestal 6530 and base 6510 is not shownin FIG. 65. Holes 6535 allow upper pedestal to be secured to base 6510in a multiple discrete rotational locations. Base 6510 may compriseholes 6517 a, 6517 b for securing base 6510 to a support structure, suchas the rafter of a building, as discussed above.

Some benefits of tile flashing mounts 200, 2000, 2100, 3300, 4000, 4600,and 6000 may include:

Enables simple method for rail-free mounting on tile roofs, which isdifficult in prior art systems since they do not typically provideenough connection flexibility along the y-axis;

Enables easy method(s) and structure(s) to resolve conflicts betweeninterlocks and leveling feet for space in groove 105 a;

Reduces or eliminates the need to grind tile(s) during a solar moduleinstallation on a tile roof (a common practice when utilizing prior arttechnology) by simply removing and replacing an entire tile, leaving thesurrounding tiles unaltered; and/or

Enables improved water-proofing or fluid-resistance for the roofcompared to prior art technology, such as tile hooks, since tile hooksrequire tile grinding which compromises the water-proofing orfluid-resistance characteristics of the tile.

FIGS. 66-68 show an embodiment of a wire retaining, restraining, routingor management device, such as wire clip 6600. Wire clip 6600 may beconnected to a PV module frame, such as frame 104 a as discussed above.FIG. 66 shows a perspective view of wire clip 6600 and FIGS. 67-68 showsection views as wire clip 6600 is being connected to frame 104 a. Wireclip 6600 may comprise a wire retaining portion 6610, a spring portion6620, a riser portion 6630, and a tooth 6640 and may be manufacturedfrom any suitable material such as metal or plastic.

Wire clip 6600 is installed as follows. Wire clip 6600 is first placedin the position shown is FIG. 67, with tooth 6640 resting against anoutside face of frame 104 a below groove 105 a and bump 6621, which maydefine a beginning to spring portion 6620, touching a bottom surface offrame 104 a. Wire clip 6600 is then pushed or pressed approximately inthe direction of the arrow shown in FIG. 67, which then results inspring portion bending open approximately in the direction of the arrowshown in FIG. 68. The pressing force may be released when spring portion6620 has opened up enough to allow tooth 6640 to enter groove 105 a andthen drop behind a lip 102 a of groove 105 a. Wire clip 6600 is now heldby the clamping action of spring portion 6620 which has been bent openand now applies a spring force approximately opposite the direction ofthe arrow in FIG. 68. Riser portion 6630 may optionally contact frame104 a above or within groove 105 a to further stabilize wire clip 6600once installed. With wire clip connected to frame 104 a, a wire, cable,ground wire, or the like, such as wire 6615, may be placed into wireretaining portion 6610. Wire retaining portion 6610 may comprise apress-fit mechanism for holding wires or it may loosely hold wires andit may comprise multiple-sized press-fit portions for accommodatingdifferent diameters of wires.

FIGS. 69-71 show an embodiment of a wire retaining, restraining, routingor management device, such as wire clip 6900. Wire clip 6900 may beconnected to a PV module frame, such as frame 104 a. FIG. 69 shows aperspective view of wire clip 6900 and FIGS. 70-71 show section views aswire clip 6900 is being connected to frame 104 a. Wire clip 6900 maycomprise a wire retaining portion 6910, a spring portion 6920, a riserportion 6930, and a tooth 6940 and may be manufactured from any suitablematerial such as metal or plastic.

Wire clip 6900 is installed as follows. Wire clip 6900 is first placedin the position shown is FIG. 70, with riser portion 6930 adjacent to anoutside surface of frame 104 a and tooth 6940 located at least partiallyinside groove 105 a and at least partially behind lip 102 a. A wire,cable, ground wire, or the like, such as wire 6915 is then pressedbetween wire retaining portion 6910 and a bottom surface of frame 105 a,which results in wire clip dropping down to the position shown in FIG.71 and spring portion bending open approximately in the direction of thearrow shown in FIG. 68. The pressing force may be released when springportion 6920 has opened up enough to allow wire 6915 to fully seat inwire retaining portion 6910. In its final position tooth 6940 iscaptured behind lip 102 a. Wire clip 6900 is now held by the clampingaction of spring portion 6920 which has been bent open and now applies aspring force approximately opposite the direction of the arrow in FIG.68. Riser portion 6930 may optionally contact frame 104 a above orwithin groove 105 a to further stabilize wire clip 6900 once installed.

FIGS. 72-74 show an embodiment of a wire retaining, restraining, routingor management device, such as wire clip 7200. Wire clip 7200 may beconnected to a PV module frame, such as frame 104 a as discussed above.FIG. 72 shows a perspective view of wire clip 7200 and FIGS. 73-74 showsection views as wire clip 7200 is being connected to frame 104 a. Wireclip 7200 may comprise a wire retaining portion 7210, a spring portion7220, a riser portion 7230, and a tooth 7240 and may be manufacturedfrom any suitable material such as metal or plastic.

Wire clip 7200 is installed as follows. Wire clip 7200 is first placedin the position shown is FIG. 73, with tooth 7240 resting against anoutside surface of frame 104 a below groove 105 a and bump 7222, whichmay define a beginning to spring portion 7220, touching a top surface oflower flange 174 of frame 104 a. Wire clip 720 is then pushed or pressedat 7231 approximately in the direction of the arrow shown in FIG. 73,which then results riser portion 7230 bending approximately in thedirection of the right arrow shown in FIG. 74. Once bump 7221 contactsframe 105 a, spring portion 7220 bends open approximately in thedirection of the left arrow shown in FIG. 74 to allow tooth 7240 to gethigh enough up to enter groove 105 a. The pressing force may be releasedwhen spring portion 7220 has opened up enough to allow tooth 7240 toenter groove 105 a. Wire clip 7200 is now held by the force delivered byspring portion 7220 which results in a downward force at tooth 7240,effectively pushing it down against lip 102 a. With wire clip connectedto frame 104 a, a wire, cable, ground wire, or the like, such as wire7215, may be placed into wire retaining portion 7210. Wire retainingportion 7210 may comprise a press-fit mechanism for holding wires or itmay loosely hold wires and it may comprise multiple-sized press-fitportions for accommodating different diameters of wires.

Referring now to FIGS. 1-4, various views of a leveling foot are shown.A leveling foot such as leveling foot 110 may include, withoutlimitation, a base 140 with a slot 143, a stud 130, and a coupling 120with male portions such as a tongue side 122 and a key side 121 wherethe key side includes an upper jaw 187 and a lower jaw 188.

Referring now to FIG. 5, an isometric view of a grounding clip is shown.A grounding clip such as clip 124 may include teeth 196, edges 125, andedges 126. Grounding clip 124 may comprise a portion of leveling foot110 and may engage coupling 120 by being pressed between upper jaw 187and lower jaw 188 such that teeth 196 face upward and are closer to thetongue side 122 than the key side 121. Edges 125 and 126 may penetratethe exterior surface of the frame of a PV module when such a module isinstalled on the coupling 120, and teeth 196 may penetrate the exteriorsurface of the coupling 120, creating a grounding connection between allcomponents.

Referring now to FIG. 6, a cross section of a leveling foot 110 and twoPV modules 100A and 100B is shown with the key side 121 engaging theframe of PV module 100A. An exterior portion of the frame of PV module100B rests atop coupling 120 of leveling foot 110.

Referring now to FIGS. 7 and 8, a cross section of a leveling foot 110and two PV modules 100A and 100B is shown with the key side 121 engagingthe frame of PV module 100A and two positions of PV module 100Bindicating how PV module 100B engages coupling 120. FIG. 8 is anenlarged version of Area A of FIG. 7. Upon installation, key side 121may compress as a spring under load, moving upper jaw 187 and lower jaw188 closer to one another, and such compression may allow fortolerances. Simultaneously, the upper jaw 187 and lower jaw 188 mayfurther pry open a groove integrated into a frame of a PV module 100B.

Referring now to FIG. 9, a flashing 220 is shown installed on a base 210(also referred to as a support). Connected to base 210 is an upperpedestal 230 (also referred to as a top arm). A leveling foot 110 isconnected to the upper pedestal 230. Base 210 may serve as a supportstructure and may include a vertical component and a horizontalcomponent. Flashing 220 may include an upper surface and a lower surfaceand may feature a curvilinear shape that reflects the shapes of adjacenttiles.

Referring now to FIG. 10, a side view of the components of FIG. 9 isshown. Base 210 is shown affixed to rafter 204 using lag screws 211. Inthe instant embodiment, rubber seal 221 is placed between base 210 andflashing 220. Upper pedestal 230 is connected onto flashing 220 bypassing fasteners 212 into base 210 and securing the connection withnuts 213. Leveling foot 110 is then connected to upper pedestal 230 bypassing a fastener 212 (not shown) through a slot in the base ofleveling foot 110 to engage upper pedestal 230.

Referring now to FIG. 10A, an isometric view of flashing 220 is shown.Flashing 220 may include overlapping portion 225 and side interleavingportion 226. Overlapping portion 225 and side interleaving portion 226may be shaped to engage adjacent roof tiles such that flashing 220engages adjacent roof tiles as though flashing 220 were a roof tileitself

Referring now to FIG. 11, a roof such as roof 10 is shown with a missingtile 201.

Referring now to FIG. 12, base 210 with holes 218 is placed on roof 10.

Referring now to FIG. 13, flashing 220 is placed atop base 210 such thata pair of holes 223 aligns with holes 218.

Referring now to FIG. 14, upper pedestal 230 is placed onto flashing220.

Referring now to FIG. 15, another configuration of base 210, flashing220, and upper pedestal 230 is shown.

Referring now to FIGS. 16-18, multiple views of an upper pedestal areshown. An upper pedestal such as upper pedestal 1630 is similar to upperpedestal 230 as shown and described in FIG. 9 and others, and to otherupper pedestals. Upper pedestal 1630 may include slots 1635 and 1636that may align with holes 223 and holes 218, shown and described inFIGS. 12 and 13.

Referring now to FIG. 19, an alternate embodiment of a base is shown.

Referring now to FIG. 20, an alternate configuration of a base 2210,flashing 2220, and leveling foot 110 is shown where no upper pedestalappears between the flashing 2220 and the leveling foot 110.

Referring now to FIG. 21, an alternate upper pedestal, flashing, andbase are shown. An upper pedestal such as upper pedestal 2130 is similarto upper pedestal 230 as shown and described in FIG. 9 and others, toupper pedestal 1630 as shown and described in FIG. 16 and others, and toother upper pedestals. A base such as base 2110 is similar to base 2210as shown and described in FIG. 20 and others, and to other bases. Aflashing such as flashing 2120 is similar to flashing 2220 as shown inFIG. 20 and others, and to other flashings.

Referring now to FIG. 22, a side view of the components of FIG. 21 isshown.

Referring now to FIG. 23, an isometric view of flashing 2120 is shown.

Referring now to FIGS. 24-28, various views of upper pedestal 2133 areshown.

Referring now to FIGS. 29-32, the installation sequence of thecomponents of FIG. 21 is shown.

Referring now to FIG. 33, an alternate upper pedestal, flashing, andbase are shown. An upper pedestal such as upper pedestal 3330 is similarto upper pedestal 230 as shown and described in FIG. 9 and others, toupper pedestal 1630 as shown and described in FIG. 16 and others, and toother upper pedestals. A base such as base 3110 is similar to base 2210as shown and described in FIG. 20 and others, and to other bases. Aflashing such as flashing 3320 is similar to flashing 2220 as shown inFIG. 20 and others, and to other flashings.

Referring now to FIG. 34, a side view of the components of FIG. 33 isshown.

Referring now to FIG. 34A, a bottom-isometric view of upper pedestal3330 is shown.

Referring now to FIG. 35, an isometric view of flashing 3320 is shown.

Referring now to FIGS. 36-39, the installation sequence of thecomponents of FIG. 33 is shown.

Referring now to FIG. 40, an alternative embodiment of a base is shown.Base 4010 is similar to base 3310 as shown and described in FIG. 36 andothers, and to other bases.

Referring now to FIGS. 41 and 42, an alternative embodiment of aflashing is shown. Flashing 4020 is similar to flashing 3320 as shownand described in FIG. 33 and others, and to other flashings. Asdescribed further below, flashing 4020 is formed to engage base 4010.

Referring now to FIGS. 43-45, flashing 4020 is shown installed on base4010 and then connected to a leveling foot.

Referring now to FIG. 46, an alternate embodiment for installing aleveling foot on a roof through a flashing is shown.

Referring now to FIG. 47, an embodiment of a flashing is shown. Flashing4620 is similar to flashing 4020 as shown and described in FIG. 43 andothers, and to other flashings.

Referring now to FIG. 48, the top portion of the components of FIG. 46is shown.

Referring now to FIGS. 49-52, the installation steps for the componentsof FIG. 46 are shown.

Referring now to FIGS. 53 and 54, a shingle flashing mount is shown. Ashingle flashing mount such as shingle flashing mount 5300 may includeflashing 5310, base 5320, threaded pedestal 5330, and platform 5335.

Referring now to FIG. 55, PV module 1000 is shown connected to a shingleflashing mount. FIG. 56 is an enlarged view of area B of FIG. 55.

Referring now to FIG. 56, PV module 1000 is shown resting atop platform5335. Clip 5610 then engages groove 1005 and platform 5335 to secure PVmodule 1000 to shingle flashing mount 5300.

Referring now to FIGS. 57-59, a metal roof mount is shown. A metal roofmount such as metal roof mount 5700 may connect a leveling foot to atrapezoidal roof

Referring now to FIG. 60, an alternative embodiment of an upper arm isshown. An upper arm such as upper arm 6030 may connect a PV module to atile roof using a clip such as clip 6098 rather than a leveling foot.

Referring now to FIGS. 61-64, multiple views show a PV module connectingto a top arm using a clip.

Referring now to FIG. 65, yet another embodiment of a base 6510 and toparm 6500 are shown.

Referring now to FIGS. 66-74, embodiments of wire clips are shown. Wireclips 6600, 6900, and 7200 engage a wire and the groove 105A of a frameto capture the wire.

While a number of exemplary aspects and embodiments have been discussedabove, those of skill in the art will recognize certain modifications,permutations, additions and sub-combinations thereof. It is thereforeintended that the following appended claims and claims hereafterintroduced be interpreted to include all such modifications,permutations, additions, and sub-combinations as are within their truespirit and scope.

What is claimed is:
 1. An apparatus for mounting a photovoltaic (“PV”)module on a structure comprising: a base portion, a stud portion, and acoupling portion wherein a male portion acts as a spring under load anda clip portion penetrates the PV module frame to create a groundingbond.
 2. The apparatus of claim 1 with a lower jaw shaped to pry open agroove.
 3. The apparatus of claim 1 with a key portion that compressesto allow for tolerances.
 4. A method for mounting photovoltaic (“PV”)modules on a structure comprising steps: securing a base of a levelingfoot to a substrate or structure; inserting a key portion of a couplinginto a groove of a first PV module at an angle between five andseventy-five degrees; rotating the first PV module downward toward thesubstrate or structure until parallel with the substrate or structure,thereby causing the key portion to engage fully the groove, causingspring contraction of the key, and causing spring expansion of thegroove; resting an outside surface of the frame of a second PV module ona top surface of the coupling portion such that the second PV module isat a ninety degree angle to the substrate; and rotating the second PVmodule downward until roughly parallel with the first PV module.
 5. Aclip apparatus comprising: a clip; one or more tabs; one or more teeth;wherein one or more tabs secure the clip to a coupling portion and oneor more teeth penetrate: (i) a surface of a PV module when the PV moduleengages the coupling portion, and (ii) a surface of the coupling portionwhen the clip engages the coupling portion, thereby creating anelectrical ground bond between the clip, the coupling portion, and thePV module.
 6. A replacement roof tile comprising: a support structurecomprising a horizontal flange, a vertical component, and a horizontalcomponent; a flashing with an upper surface and a lower surface; and atile-shaped metal surface having a curvilinear shape that reflects ashape of a plurality of adjacent tiles.
 7. The replacement tile of claim6, wherein the replacement roof tile comprises a conical supportstructure and a flashing with a circular aperture.
 8. A method formounting a replacement roof tile comprising steps: mounting a supportstructure on a substrate; mounting a tile-shaped metal surface on thesupport structure; mounting a top arm to the support structure over,above, or atop a tile-shaped metal surface; mounting a leveling footonto the top arm; and mounting a PV module to the leveling foot.
 9. Themethod of claim 8 further comprising steps: wherein the top arm islaterally applied to the support structure and the tile-shaped metalsurface.
 10. The method of claim 8 further comprising steps: wherein adevice connects to the support structure and the tile-shaped metalsurface using a coupling.
 11. An apparatus for mounting a photovoltaic(“PV”) module comprising: a flashing; a vertical component; and a planarcomponent with an upper surface and a lower surface thereby enablingsimplified mounting of a PV module on a tiled surface or substrate. 12.A method for connecting a photovoltaic (“PV”) array to a surface orstructure comprising steps: installing a crossbar for mounting aplurality of PV modules on a surface or structure; and laterallyengaging a planar component of the crossbar with a device that connectsto a upper and lower surfaces of the planar component.